CN1961109A

CN1961109A - Aligned fiber web

Info

Publication number: CN1961109A
Application number: CNA2005800121734A
Authority: CN
Inventors: 拉胡尔·R·沙阿; 道格拉斯·C·松诺兹; 吴天纵; 约翰·M·布兰德纳
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2004-04-05
Filing date: 2005-03-19
Publication date: 2007-05-09
Anticipated expiration: 2025-03-19
Also published as: KR20070028347A; KR101193785B1; US6858297B1; JP2007531831A; RU2006134440A; WO2005100661A1; EP1733086B1; ATE536431T1; BRPI0509604A; EP1733086A1; CN1961109B; JP4955536B2

Abstract

Nonwoven webs having substantially aligned fibers can be formed in an apparatus having a direction of motion corresponding to the direction of web formation. The web is formed in the presence of at least one secondary fluid stream that oscillates the filaments or resulting attenuated fibers to and fro generally in and against the direction of motion so that a majority of the collected fibers are aligned within +/-20 degrees of the direction of motion and fibers having lengths of about 1 - 10 cm can be teased from the web. The resulting nonwoven webs are especially useful for forming pleated filtration media having pleats generally transverse to the direction of motion.

Description

Aligned fiber web

Technical field

The present invention relates to the method for fibrous filter net and this net of manufacturing, and on wherein net presents vertically (machine direction, fiber alignment MD), and have 1 centimetre to 10 centimetres length.

Background technology

The melt-blown non-woven fiber web serves many purposes, and comprises filtration (for example, plain net and pleated filter), insulation, fills and the weaving substitute.The fibroreticulate list of references of relevant melt-blown non-woven comprises United States Patent (USP) 3,959,421 (Weber etc.), 4,622,259 (McAmish etc.), 5,075,068 (Milligan etc.), 5,141,699 (Meyer etc.), 5,405,559 (Shambaugh), 5,652,048 (Haynes etc.), 5,665,278 (Allen etc.), 5,667,749 (Lau etc.), 5,772,948 (Chenoweth) and 5,811,178 (Adam etc.).The list of references of relevant pleated filter comprises United States Patent (USP) 4,547,950 (Thompson), 5,240,479 (Bachinski), 5,709,735 (Midkiff etc.), 5,820,645 (Murphy, Jr.), 6,521,011B1 (Sundet etc., ' 011 patent), and U.S. Patent Application Publication US 2003/0089090A1 (Sundet etc., ' 090 patent) and US 2003/0089091 A1 (Sundet etc., ' 091 patent).

Summary of the invention

Making nonwoven web is usually directed to the surface of fiber laydown in the gatherer that moves.Perhaps partly because this mobile result, the net of collected one-tenth can demonstrate slight fiber alignment on vertically, and less some the anisotropic physical property (for example, TENSILE STRENGTH) of the degree that demonstrates on vertical and horizontal.But the nonwoven web producer usually strives making goods to have equilibrium and isotropic basically physical property.

We have found that to have the nonwoven web of arranging much bigger fiber alignment than general fibre by being formed on machine direction, we can obtain to have the net of the strainability of the mechanical performance of improvement or improvement.The net of making has for formation and crosses basically longitudinally that the pleated filter media of pleat is particularly useful.An aspect the invention provides a kind of method that is used to form fibrous filter net, comprising:

A) under the situation that has first fluid stream, by nozzle array, the thermoplastic that forms fiber is melted and sprayed, to form plurality of threads, this long filament is drawn into fine fibre and is directed to the porous with direction of motion collects the surface;

B) make at least that one second fluid stream impacts on long filament or the fiber so that fiber roughly along or swing to and fro against the direction of motion; And

C) collect porous and collect lip-deep fiber, to form the non-woven net that melts and sprays;

Wherein the second fluid stream causes fiber fully to be swung, thus most of collected fiber alignment the direction of motion ± 20 ° in, and wherein, in the net of not heat-treating, to play length be about fiber of 1 to about 10cm in combing from network.

On the other hand, the invention provides a kind of fiber filter material of form of net, this netting gear has corresponding to the length direction of the prolongation that becomes the net direction with perpendicular to the narrow width of this length direction, this net comprises the non-woven thermoplastic fiber, wherein great majority be arranged in the direction of motion ± 20 ° in, and wherein, in the net of not heat-treating, to play length be about fiber of 1 to about 10cm in combing from network.

By following detailed description, these and other aspects of the present invention will be more clear.

But, never should be above summary content interpret for for the restriction of requirement theme, this theme is only limited by the claim of being added, and can make amendment in the application of patent and checking process.

Description of drawings

Fig. 1 is the diagrammatic side view of melt-blowing equipment, and this melt-blowing equipment is used to make and has basically the nonwoven web of vertically arranging.

Fig. 2 is the vertical view that is used for the vacuum collecting device of equipment shown in Figure 1.

Fig. 3-Fig. 6 is the radar mapping figure that fiber alignment is shown.

Fig. 7 is the shaft side figure of pleated filter media.

Fig. 8 is the shaft side figure that part is cut open, and the pleated filter that is installed in the framework is shown.

Fig. 9 is that the curve that in contrast to air velocity falls in expression filter pressure.

Identical Reference numeral is represented identical part in the different accompanying drawings.Each part and not drawn on scale in the accompanying drawing.

The specific embodiment

Term " nonwoven web " is meant the entanglement that is characterised in that fiber or the fiber web of point bonding.

Term " screen pack " is meant such porous net, and it can be fallen at the initial pressure that is no more than about 50mm water column, from the 0.5m/ superficial velocity flow air stream of second, removes the particle of average grain diameter greater than 10 μ m at least.

Term " is drawn into fine fibre with long filament " and is meant, segment length's silk is converted into the fiber fragment that length is longer and diameter is littler.

Speech " melts and sprays " such method that is meant, extrude to form long filament by running through the material that a plurality of spouts will form fiber, long filament ingress of air or other are stretched with fluid so that long filament becomes fine fibre, collect the fibrage that stretches then, the formation nonwoven web.

Term " meltblown web " is meant the nonwoven web that utilizes melt-blown process to make.

Term " non-woven mould " is meant the mould that uses in melt-blown process.

Term " meltblown fibers " and " blown microfiber " are meant the fiber that utilizes melt-blown process to make.

About meltblown web or be used for the interior direction of face that the employed term of melt-blowing equipment " vertically " that meltblown web is shaped is meant the system net.

Be meant direction in the face that crosses longitudinally about melt-blowing equipment or the employed term of meltblown web " laterally ".

Be meant such direction about the folding employed term of filter element " direction of row ", this direction is arranged essentially parallel to pleat ridge and the paddy in the filter element (having the roughly foldable structure of the parallel pleat trace of sharp edges), and refer to that such direction, this direction are arranged essentially parallel to pleat top and the bottom section in the filter element (ripple struction with level and smooth basically parallel wavy shape).

Be meant such net about netting employed term " self-supporting ", it has enough caking abilities and intensity, so that can wrinklingly there not be substantial tearing or breakage with handling, and be meant such filter when using about pleated filter, its pleat has enough rigidity, thereby when being subjected to the action of air pressure that in the pressure air ventilation systems, is run into usually, can not collapse or overbending.

Can use multiple polymers to make disclosed aligned fiber web.Typical polymers comprises for extruding and can utilize the thermoplastic of melt-blowing equipment processing: polyolefin, as polyethylene, polypropylene or polybutene; Polyamide; Polyester is as polyethylene terephthalate; And other materials well known to those skilled in the art.Polyolefin is particularly preferred.

If desired, multiple absorbent particles can be added in the nonwoven web.Representational absorbent particles the United States Patent (USP) 3,971,373 of authorizing Braun, authorize the United States Patent (USP) 4,429,001 of Kolpin etc. and authorize have in the United States Patent (USP) 6,102,039 of Springett etc. disclosed.Activated carbon and aluminium oxide are particularly preferred absorbent particles.Although more preferably be manufactured in each individual layer the multilayer folding filter that adopts independent absorbent particles in order to handle admixture of gas in practice,, also can use the mixture of absorbent particles, for example be used for the adsorbed gas mixture.If you are using, preferably, knot is gone into the absorbent particles of at least 80 percentage by weights in net, the absorbent particles of at least 84% percentage by weight better, and the absorbent particles of at least 90% percentage by weight preferably.

The present invention can use multiple first and second fluids stream.Air is a fluid especially easily for two kinds of purposes.Other parts of the application will be discussed the use of air, be called " first air " or " the second cooling air " during needing based on context.Those skilled in the art can easily use other fluids (for example, carbon dioxide, nitrogen or water) by suitable modification operating parameter described below.

Fig. 1 represents the diagrammatic side view of melt-blowing equipment 10.The polymer of fusion enters meltblown die 12 through inlet 14, and passes mold cavity 16.Little spout (not shown in figure 1) in the mould end 18 causes the polymer of fusion to form long filament 22 when leaving mould 12.Impact on long filament 22 by 20 first air that provide that enter the mouth, and it is drawn into fine fibre 24.Fiber 24 drops on the flat gatherer 26, and forms nonwoven web 28, by the suitable equipment that tightens up (not shown in figure 1), can on one-tenth net direction (that is, vertical) 30 nonwoven web 28 be dragged away from gatherer 26.Provide pipe 32, the second cooling air of arranging to crossing net 28 width on the distance that arrives gatherer 26, to impact on long filament or the fiber the second cooling air, cause fiber roughly vertically and on vertically swinging back and forth.Compare with the situation that the second cooling air is not provided, the collection fiber in made net 28 is arranged basically more in the vertical.Compare during air with not using second cooling, the vertical and horizontal mechanical performance of net (for example, its vertical and horizontal rigidity and TENSILE STRENGTH) also presents bigger anisotropy.

Utilize high-speed photography from the side (or laterally) see that fiber 24 is layered on the gatherer 26 in " paintbrush is smeared " mode.Measure on gatherer, swing can have very large pitch amplitude, for example, arrives 1/4th of collector distance (" DCD ") greater than mould, and surpasses DCD half in some cases.Several conditions of work are desirable especially for obtaining this paintbrush painting type deposition.For example, swing can occur regularly, can be in arriving the distance of gatherer the increase amplitude, and the wavelength that has for a complete cycle can be less than the distance from the second cooling air outlet slit to gatherer.Preferably, not oversize from the second cooling air outlet slit to the distance of gatherer.In some cases, on the distance that arrives gatherer, fiber can present the action of whip shape in their the highest length travel place, and can temporarily move towards meltblown die, rather than always moves towards gatherer.Along with the action appearance of this whip shape, can see tangible fibrous fracture sometimes.

We can utilize tweezers to go out to have the fibre fluff of discrete length (for example, about 1 and approximately between the 10cm, being attended by accidental shorter or longer fiber) from collected online combing.Usually, be difficult to make any fiber (or fiber of any this length) to leave conventional nonwoven web, because fiber constrains in the net by the bonding of fiber and fiber or by interfibrous entanglement usually.

Can be like this with net 28 folding or further processing.For example, can use heat treatment (for example, unshowned equipment among Fig. 1 is used in annealing) to make the net hardening.Overheating Treatment can not make more difficult combing from network go out fibre fluff, because fiber can tend to rupture and net may have bonding or entanglement between stronger fiber.Preferred annealing time and temperature depend on multiple factor, and these factors comprise employed polymer fiber.Instruct as generality, recommend annealing time and temperature be about 100 ℃ up to melting point polymer, the duration is less than about 10 minutes.

Randomly, can vacuumize help by spout 34 and consolidate net 28.But, excessively densification (for example, utilizing calendaring technology) can be destroyed the filter capacity of netting.Can by as authorize the United States Patent (USP) 5 of Angadjivand etc., 496,507 disclosed fiber is contacted with water make its charged, as to authorize Klasse etc. United States Patent (USP) 4,588,537 disclosed corona treatment, for example authorize the United States Patent (USP) 5,908 of Rousseau etc., 598 disclosed aquations chargings (hydrocharging) or authorize the United States Patent (USP) 4 of Brown, 798,850 disclosed triboelectric chargings are given fiber electric charge.Also additive can be comprised in fiber to improve strainability, mechanical performance, ageing properties, surface property or other interested features of net.Representational additive comprises filler, nucleator (for example, MILLAD ^TM3988 dibenzylidene sorbitols can be buied from Milliken Chemical), UV light stabilizing agent (for example, CHIMASSORB ^TM944 hindered amine as light stabilizer, can buy from Ciba Specialty Chemicals), curing initiator, curing agent (for example, poly(4-methyl-1-pentene)), surfactant and surface treatment (for example, authorized the United States Patent (USP) 6,398 of Jones etc., 847B1,6,397,458B1 and 6,409, the disclosed fluorine atom of 806B1 is handled, to improve strainability in the mist of oil environment).The type of these additives and addition are known to those skilled in the art.

The net of finishing can have multiple effective fiber diameter (" EFD ") size, basis weight and compactedness (ratio that polymer volume is long-pending with respect to dictyosome) value.For flat blown microfiber (" BMF ") filter course, preferred EFD is about 3 to about 25 μ m (more preferably for about 7 to about 25 μ m), and is about 10 to about 25 μ m for the preferred EFD of BMF pleated filter.For flat BMF filter course, base of optimum selection weight is about 15 to 100g/m ², be about 50 to about 100g/m for BMF pleated filter base of optimum selection weight ²For BMF filter course or the preferred compactedness value of BMF pleated filter is about 5 to about 15%.

Disclosed netting gear has substantially vertically (direction of motion or one-tenth net direction) fiber alignment.As the general guide that uses the net of being made by polypropylene, preferably, about 55% to about 90% fiber becomes ± 20 ° of arrangements with respect to the direction of motion, and more preferably is about 70 to about 85%.For the net of being made by other polymeric materials, numerical value can be lower or higher.For example, as the general guide of the net of being made by polyethylene terephthalate, about preferably 51% to about 80% fiber becomes ± 20 ° of arrangements with respect to the direction of motion, and is preferably about 60% to about 80%.As the basic guide of the net of being made by nylon, preferred about 51% to about 70% fiber becomes ± 20 ° of arrangements with respect to the direction of motion.Can form very high arrangement net, for example, at least 80% collection fiber becomes the net of ± 10 ° of arrangements with respect to the direction of motion.

Disclosed netting gear has one or more anisotropic mechanical performance.When using the full-length of 50mm, a class preferred net is at least 2: 1 at face in-draw intensity on the direction of motion and the ratio that crosses the TENSILE STRENGTH on the direction of motion, more preferably at least 3: 1.Taber rigidity is at least 2: 1 with the ratio that crosses the Taber rigidity on the direction of motion in the face of another kind of preferred net on the direction of motion, more preferably about at least 2.2: 1.

May be under the condition that disclosed aligned fiber web is not provided, or under the condition that the shaky net that is unsuitable for filtering is provided, make up disclosed melt-blowing equipment and move this equipment.For example, if do not adopt the second enough cooling air, so above-mentioned swing can not occur and fiber can be basically in vertical arrangement.Too high cooling velocity can produce the bonding and the bulk net less and that strainability improves that tangles between fiber, but mechanical performance such as rigidity and folding ability seriously undermine.Therefore generally preferably adopt mass flow ratio or the volume second cooling air within the specific limits.As utilizing polypropylene and being cooled to second air example into the net that temperature is lower than ambient temperature, the polymer of extruding for every gram, the second cooling air is that about 500 ratios to about 2000 grams are preferred, and the speed of the second cooling air in the exit can be about 15 to about 60m/ seconds.Based on some factors, meltblown die and polymer, target basis weight, target network compactedness and target fibers degree of alignment and target anisotropy of mechanical properties degree as being adopted may need empirically to adjust these scopes.Can also adopt the second cooling air impulsive motion, but this is not essential.By comparison, more preferably, simply second cooling air flow is adjusted up or down, made to be gathered into the steady state value that net can have desirable final performance.

Fig. 2 represents the diagrammatic top view of gatherer 26.Mould 12 is placed near the leading edge of gatherers 26, but can move to such position, position 36 along row off the net, so that change the performance of net 28.This position is changed can for example provide the net with the Taber rigidity that reduces.If adopt conventional cylindrical collector surface rather than flat gatherer, so usually can its fiber of more difficult acquisition basically at the net of vertically arranging, and net can have lower Taber rigidity.DCD length is excessive or long to the distance of gatherer from the second cooling air outlet slit, also may be for example owing on the distance of arrival gatherer, cause too many swing, excessive tensile fiber or excessive fibrous fracture and damage.

More details of the mode that relevant utilization equipment realization as depicted in figs. 1 and 2 melts and sprays are known to those skilled in the art.

If desired, can utilize multiple technologies further to make weaving filter net rigidization.For example, can adopt adhesive that the layer of net is laminated in together, for example United States Patent (USP) 5,240, disclosed in 479 (Bachinski).For example also can utilize the disclosed composite fibre of United States Patent (USP) 5,709,735 (Midkiff etc.) to make net.

Fibrous filter net can use in multiple application, (for example comprise ventilation, stove and clean room's filter), (for example pollute control, the dust storage chamber filter), liquid handling (for example, water filter), personal protection (for example, filter mask), chemistry or bioanalysis (for example, affinity film), medical supply (for example, dialysis machine) and other application well known to those skilled in the art.Pleated filter media is particularly preferred application.For example, Fig. 7 represents to have the pleated filter media 100 of the pleat 102 of embarking on journey.These row are arranged in the horizontal, and to be the fiber arranged basically in the net 100 become 90 ° ± 20 ° arrangements with respect to the direction of row, that is, and and with respect to vertical one-tenth ± 20 °.Fig. 8 illustrates pleated filter media 100 and is installed in the framework 112 so that the net form metallic supports 110 of filter 114 to be provided.Can think that the rigidity of the increase of folded medium 100 is arranged both with the basic longitudinal fiber that crosses capable direction, can both be increased in folded medium 100 anti-pleat deformation ability under the high filter surfaces speed.About more details of this pleated filter media can submit on the same day with this case and the application of title for the common unsettled U.S. Patent Application Serial Number (application attorney docket 59583US002) of " pleated aligned web filter (PLEATED ALIGNED WEB FILTER) " in find, its content is incorporated this paper by reference into.

Describe the present invention referring now to following non-limitative example, wherein, unless indicate in addition, all parts and percentage all are to remember by weight.Several measurements of being carried out are as follows:

Effective fiber diameter

According to Davies, C.N., " airborne dust separates with particle ", and IMECHE Instiution of Mechanical Engineers (Institution of Mechanical Engineers), London, procceedings 1B, 1952 illustrated methods are estimated effective geometric fibre diameter.

Optics/net performance directly perceived

Utilization is equipped with the Cai Si instrument of the disecting microscope of charge coupled device camera, comes the whole outward appearance of net is intuitively estimated, and this camera has the amplification window of 8mm * 14mm.

Taber rigidity

The rigidity of net is utilized Model 150-B TABER ^TMRigidity testing instrument (can buy) from TaberIndustries measure.Utilize square section that sharp blade downcuts 3.8cm * 3.8cm from network carefully preventing the fiber fusing, and utilize the sample deflection of 3 to 4 samples and 15 ° that it is evaluated and tested, to determine their rigidity on vertical and horizontal.

Stress-strain

Stress-strain (or load contrast elongation) can utilize Model 5544 INSTRON ^TMOmnipotent test machine (can buy from Instron Corp.) is measured.Utilize sharp blade to downcut the rectangle section of 2.5cm * 6.3cm from network, and utilize 6 to 10 samples, the pawl initial separation of 50mm and the draw speed of 3cm/min, to power and the elongation under maximum, force effect of its evaluation and test with definite maximum.

The filter quality factor

Utilize TSI ^TMModel 8130 High-Speed Automatic filter test instrument (can buy from TSI Inc.) with mobile dioctyl phthalate (" DOP ") the test aerosol of the speed of 42.5L/min, are determined filter quality factor (Q _F).In filter inlet and exit, the photometer of employing calibration is measured DOP concentration and is seen through the DOP% of filter.Adopt MKS pressure sensor (can buy) to measure the pressure that passes filter and fall (Δ P, mm water column) from MKS instruments.Utilize equation:

Calculate Q _FQ _FValue can be to describe different time cycle Q afterwards _FThe curve form of contrast DOP test gross mass is reported out.But, initial Q _FValue has been indicated overall performance usually reliably, has higher initial Q _FValue has shown strainability preferably, and has lower initial Q _FValue has shown the strainability that reduces.Preferably, inceptive filtering factor of quality Q _FFor at least 0.6 (the 100ppm dioctyl phthalate particle that uses particle size range between 10 to 700nm, with the superficial velocity of 7cm/ second, to advance), be more preferably about at least 0.8, and most preferably about at least 1.

Strainability

Strainability is according to ASHRAE standard 52.2, and " testing the method (Method of Testing GeneralVentilation Air-Cleaning Devices for Removal Efficiency by ParticleSize) that common vent air purifier is got rid of efficient by granular size " evaluates.The ASHRAE criterion evaluation is tested aerocolloidal filterability, and this test aerosol comprises the potassium chloride particle of the laboratory generation that is dispersed in the air-flow.12 particles in the particle size range are measured and added up to particle collector at the upstream and downstream of filter.Can the result be reported with the form of the endocorpuscular minimum combined efficiency value of different grain size scope.Filter is subjected to the load effect that the final pressure of 25.4mm water column falls, and minimum combined efficiency value keeps percentage corresponding to smallest particles, and (for the particle size range of being considered, this percentage is: downstream grain count/upstream particle counting * 100).Can also work out one group of granular size that is under the increment dust carrying grade and get rid of efficient (PSE) performance curve, and can be used for forming the composite curve of lowest performance in each particle size range of expression with the initial purge performance curve.Point on the composite curve is by average computation, and mean value is used for determining the minimum efficiency report value (MERV) of filter.

Example 1-3 and comparative example 1

Polypropylene net

By as shown in Figure 1, increase and arrange second air cooling system and level bed gatherer, the wide melt-blowing equipment of the 20.5cm of routine is improved.In the spray microfiber technical process of routine, do not use the second cooling air, and net is collected on circular surface such as the porous drum.Equipment after the improvement is used for making the fusion-jetting polypropylene net, and its fiber is vertically highly being arranged.Second air cooling system adopt the 76cm of two relative horizontal positioned wide * air outlet slit that 51cm is high, this air outlet slit is arranged in the following approximately 6cm place of meltblown die end, provides and delivers out and flows through 12-13 ℃ refrigerating gas of air outlet slit with friction speed (or partial velocity difference).The level bed gatherer uses the vacuum collecting system that is positioned under the bed.Meltblown die is positioned at gatherer leading edge top.FINA ^TMType 3960 polypropylene (can buy from Fina Oil and Chemical Co.) are with 265 ℃ of down fusions the extruder of work, and are fed in the meltblown die with the speed of 9.1kg/hr.Utilize the resistive heater heats mould and keep about 265 ℃, and to 300 ℃ of mould supplies with 4.2m ³First air that the speed of/min flows.Adjust DCD to have the net that the 0.5mm water column pressure falls under the flow velocity that is provided at 32.5L/min.For the net that utilizes the second cooling air preparation, DCD is approximate 20cm.For the net of the second cooling air preparation of no use, DCD is approximate 34cm.Adjusting collector vacuum is the net of 8-9% so that compactedness to be provided.For utilizing exit velocity is 50 or the prepared net of the second cooling air of 35m/ second, and collector vacuum is 3250N/m ², for utilizing exit velocity to be the 17m/ prepared net of the second cooling air of second, collector vacuum is 5000N/m ², for need not second the prepared net of cooling air then be zero.The netting gear of collected one-tenth has 80g/m ²Basis weight and the EFD of 19 μ m.Net is carried out as United States Patent (USP) 4,588, the 537 described corona treatment of authorizing Klasse etc., as authorizing United States Patent (USP) 5,908, the 598 described aquations chargings of Rousseau etc., and it is evaluated and tested to determine their mechanical performance and filter quality factor Q _FAlso net is carried out 5 minutes heat treatment and evaluation and test again, to determine their mechanical performance at 126 ℃.

Below to list in table 1 be at the instance number of each net or comparative example number, second air velocity and mass flow ratio, fiber counting and fiber alignment data and filter quality factor Q _FBelow what list in table 2 is at vertical (" MD ") of each net and horizontal (" TD ") Taber rigidity and tensile strength values, and the Taber rigidity of MD and TENSILE STRENGTH are with respect to the ratio of TD.Below what list in table 3 is MD and TD Taber rigidity and tensile strength values at the heat treatment net, and the Taber rigidity of MD and TENSILE STRENGTH are with respect to the ratio of TD.

Table 1

Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	The fiber sum that records	The 0-10 of MD ° with interior fiber number	The 0-10 of MD ° with interior fiber (%)	The 0-20 of MD ° with interior fiber number	The 0-20 of MD ° with interior fiber (%)	The filter quality factor, Q _F
Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	The fiber sum that records	The 0-10 of MD ° with interior fiber number	The 0-10 of MD ° with interior fiber (%)	The 0-20 of MD ° with interior fiber number	The 0-20 of MD ° with interior fiber (%)	The filter quality factor, Q _F	1	50	1770	38	30	80	34	89	1.65
2	35	1450	33	20	61	27	82	1.5	1	50	1770	38	30	80	34	89	1.65
2	35	1450	33	20	61	27	82	1.5	3	17	720	32	16	50	32	56	0.85
Comparative example 1	0	0	33	11	33	33	57	0.7	3	17	720	32	16	50	32	56	0.85

Table 2

Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	Taber rigidity, MD	Taber rigidity, TD	Ratio, Taber rigidity MD: TD	TENSILE STRENGTH, MD (dyne)	TENSILE STRENGTH, TD (dyne)	Ratio, TENSILE STRENGTH MD: TD
Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	Taber rigidity, MD	Taber rigidity, TD	Ratio, Taber rigidity MD: TD	TENSILE STRENGTH, MD (dyne)	TENSILE STRENGTH, TD (dyne)	Ratio, TENSILE STRENGTH MD: TD	1	50	1770	1.3	0.6	2.2	1773	635	2.8
2	35	1450	1.9	0.7	2.7	2270	730	3.1	1	50	1770	1.3	0.6	2.2	1773	635	2.8
2	35	1450	1.9	0.7	2.7	2270	730	3.1	3	17	720	2.1	1.1	1.9	1374	1101	1.2
Comparative example 1	0	0	1.5	1.3	1.2	1670	1370	1.2	3	17	720	2.1	1.1	1.9	1374	1101	1.2

Table 3 (heat treatment)

Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	Taber rigidity, MD	Taber rigidity, TD	Ratio, Taber rigidity MD: TD	TENSILE STRENGTH, MD (dyne)	TENSILE STRENGTH, TD (dyne)	Ratio, TENSILE STRENGTH MD: TD
Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	Taber rigidity, MD	Taber rigidity, TD	Ratio, Taber rigidity MD: TD	TENSILE STRENGTH, MD (dyne)	TENSILE STRENGTH, TD (dyne)	Ratio, TENSILE STRENGTH MD: TD	1	50	1770	1.2	0.7	1.7	2298	780	2.9
2	35	1450	1.9	0.7	2.7	2303	765	3.0	1	50	1770	1.2	0.7	1.7	2298	780	2.9
2	35	1450	1.9	0.7	2.7	2303	765	3.0	3	17	720	2.5	1.6	1.6	1770	1100	1.6
Comparative example 1	0	0	2.5	2.0	1.3	1700	1489	1.1	3	17	720	2.5	1.6	1.6	1770	1100	1.6

As shown in table 1, utilize second longitudinal fiber that net had made of cooling air to arrange significantly better than need not the made net of the second cooling air.This has further in Fig. 3 to Fig. 6 and illustrates, and these figure are polar coordinates " radar " figure that represent the number of the fiber in example 1-3 and the comparative example 1 and orientation (with respect to 0 ° of angle longitudinally) respectively.Because being orientated that fiber with respect to 0 ° of vertical one-tenth also is said to is to be oriented 180 °, so drawing appliances is relevant for the symmetrical lobes of former point reflection.For example Fig. 3 represents 12 fiber alignments for relatively vertically becoming 0 °, and 9 fiber alignments become-10 °, and 8 fiber alignments become+10 °, and 6 fiber alignments become-20 °, or the like.Fig. 3 to Fig. 5 represent disclosed vertical arrangement that net had significantly better than drawn among Fig. 6 need not second the net of cooling air preparation.In another comparative example, the net of the Fig. 4 shown in ' 749 patents of evaluation Lau etc., with fiber orientation and the fiber counting of determining it, and find only to have 50% fiber alignment longitudinally ± 20 ° in.

Fig. 3 to Fig. 5 roughly reflects the behavior of the wetting fluid on the non-collector side that places net.If a suitable wetting fluid (preferably having dyeed to help observing) is arranged like this, make the pattern of oval shapes that it tends to correspond essentially to formation radar map lobe shape be diffused in the net, thereby indicate fiber orientation and inceptive direction into the net easily.When wetting fluid placed comparative example 1 online, it more or less tended to evenly outwards diffuse to form the circular pattern of expansion.

Table 1 is also represented the increase along with the second cooling volume of air, filter quality factor Q _FAlso increase and reduce slightly then.

Have visiblely with the netting gear of second air preparation, the soft and surface of fluffing slightly of gloss is arranged generally, and seldom be with or without the brief summary of in conventional spray microfiber webs, being found basically at the striped of vertically arranging.Can utilize tweezers pull-up length from network to be approximately 2 to 5cm fiber.Need not be similar to the standard spray microfiber webs that collection forms on spherical collector in appearance by second net that cools off the air preparation.Can utilize tweezers to remove the individual fibers that some relatively lack (less than 1cm) on the net, but have very big difficulty from these.

As shown in table 2, utilize the second anisotropy Taber rigidity that net had made of cooling air obviously greater than the net that does not use the second cooling air to make.Utilize the more substantial second anisotropy TENSILE STRENGTH that net had made of cooling air obviously greater than the net that does not use the second cooling air to make.

As shown in table 3, can improve the rigidity and the TENSILE STRENGTH of net with heat treatment.Can carry out above-mentioned processing to several such nets, and can not make the overall anisotropy of mechanical properties generation material alterations of net, this machinery anisotropy is utilized MD: the TD performance recently records.

Example 4-6

The net that EFD is littler

Adopt the basic skills of example 1, utilize first air (with 3.4m ³The speed of/min flows, 300 ℃) and second cool off air and gatherer, vacuumize and prepare the fusion-jetting polypropylene net, this gatherer vacuum is adjusted to provide has 80g/m ²The compactedness of basis weight, 8-9% and effective fiber diameter than the littler collecting net that obtains in the example 1.Below what list in table 4 is instance number, second air velocity and mass flow ratio, effective fiber diameter and fiber counting and fiber alignment data for made net.

Table 4

Instance number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	EFD	The fiber total number that records	The 0-10 of MD ° with interior fibre number	The 0-10 of MD ° with interior fiber (%)	The 0-20 of MD ° with interior fibre number	The 0-20 of MD ° with interior fiber (%)
Instance number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	EFD	The fiber total number that records	The 0-10 of MD ° with interior fibre number	The 0-10 of MD ° with interior fiber (%)	The 0-20 of MD ° with interior fibre number	The 0-20 of MD ° with interior fiber (%)	4	22.5	930	13.5	38	24	63	29	76
5	20	830	13.4	41	20	49	26	63	4	22.5	930	13.5	38	24	63	29	76
5	20	830	13.4	41	20	49	26	63	6	14.5	620	7.4	43	18	42	26	60

As shown in table 4, the net with basic longitudinal fiber arrangement can be made with multiple effective fiber diameter.

Example 7-10 and comparative example 2 and 3

PET and nylon wire

Adopt the basic skills of example 1, use polyethylene terephthalate (" PET ") and nylon (ULTRAMID ^TMBS-400N nylon can buy from BASF Corp.), utilize with 2.9m ³350 ℃ first air that the speed of/min flows, and the optional second cooling air prepares nonwoven web.12.7cm DCD be used for preparing the PET net, and the DCD of 16.5cm is used for preparing nylon wire.Collected PET netting gear has 85g/m ²Basis weight, the compactedness of 5-6% and the EFD of 16 μ m.Collected nylon wire has 70g/m ²Basis weight, the compactedness of 5-6% and the EFD of 17-18 μ m.Below what list in table 5 is for the instance number of made net or comparative example number, second air velocity and mass flow ratio, employed polymer and fiber counting and fiber alignment data.

Table 5

Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	Polymer	The fiber total number that records	The 0-10 of MD ° with interior fibre number	The 0-10 of MD ° with interior fiber (%)	The 0-20 of MD ° with interior fibre number	The 0-20 of MD ° with interior fiber (%)
Instance number or comparative example number	Second air is in the speed (m/ second) in exit	Mass ratio, second air: polymer	Polymer	The fiber total number that records	The 0-10 of MD ° with interior fibre number	The 0-10 of MD ° with interior fiber (%)	The 0-20 of MD ° with interior fibre number	The 0-20 of MD ° with interior fiber (%)	7	35	1450	PET	41	26	63	32	78
8	22.5	930	PET	36	21	58	25	69	7	35	1450	PET	41	26	63	32	78
8	22.5	930	PET	36	21	58	25	69	Comparative example 2	0	0	PET	38	9	23	12	31
9	35	1450	Nylon	33	17	50	21	64	Comparative example 2	0	0	PET	38	9	23	12	31
9	35	1450	Nylon	33	17	50	21	64	10	22.5	930	Nylon	45	16	35	23	52
Comparative example 3	0	0	Nylon	38	10	26	19	50	10	22.5	930	Nylon	45	16	35	23	52

As shown in table 5, can utilize multiple polymers to make and have the roughly net of longitudinal fiber arrangement.

Example 11

Additive

Come repetition example 2 by adding 1.5% additive poly(4-methyl-1-pentene).This makes filter quality factor Q _FWhen never 1.5 during additive increases to additive 1.7.

Example 12

Additive

By adding 1.5% additive poly(4-methyl-1-pentene) and adding 0.5% CHIMASSORB 944 hindered amine as light stabilizer, come repetition example 11.Net is carried out aquation charging but do not carry out corona treatment.Filter quality factor Q _FBe 2.5, the twice of the filter quality factor that is obtained when surpass using the net of making by the not processed polypropylene spray microfiber of routine (need not the second cooling air made).

Example 13 and comparative example 4

Evaluation and test Q _FOver time

Adopt the basic skills of example 1, use and need not the second cooling air (the second cooling air with 1770: the mass flow ratio of polymer flows), corona treatment, aquation charge and prepare the fusion-jetting polypropylene net, and it is evaluated and tested to determine their filter quality factor Q _FNetting gear has 85g/m ²Basis weight, the EFD of 19-21 μ m and the pressure of the 0.4-0.5mm water column under the 42.5L/min fall.Below what list in table 6 is at using (example 13) or not using (comparative example 4) second cooling air and the Q of net after multiple accumulation DOP exposure level that make _FFactor.

Table 6

Accumulation DOP test, (mg)	The net of example 13, Q _F	The net of comparative example 4, Q _F
Accumulation DOP test, (mg)	The net of example 13, Q _F	The net of comparative example 4, Q _F	Initially	1.8	0.7
50	1	0.2	Initially	1.8	0.7
50	1	0.2	100	0.6	0.15
150	0.45	0.1	100	0.6	0.15
150	0.45	0.1	200	0.3	＜0.1

As shown in table 6, compare with the net that does not use the second cooling air in the preparation and have a less fiber alignment, use the second cooling air to make and have the net that longitudinal fiber roughly arranges obviously better strainability is provided.

Example 14 and 15 and comparative example 5-7

Folding stove filter

Through the net of the example 2 of corona treatment and aquation charging, through the net of the comparative example 1 of corona treatment and aquation charging, and ACCUAIR ^TMSpunbond polyethylene/polypropylene twisted fibres net (71g/m through corona treatment ²Basis weight ,～EFD of 20 μ m, can buy from KimberlyClark Corp.) sample, the sample of above-mentioned net is formed the high filter element of 50.8cm * 63.5cm * 2.1cm, these filter elements have the pleat 102 of folded medium 100 as shown in Figure 7.Pleat 102 is arranged like this, makes that pleat is transversely arranged, and 87 pleats (13.8 pleats/10cm) are alongst arranged.Folded medium 100 is sandwiched between the net form metallic supports (as support member 110) and is bonded to therebetween, then it is installed in the paperboard frame (framework 112 as shown in Figure 8), to form filter 114 (for the filter shape of framework is arranged).According to ASHRAE standard 52.2, " testing the eliminating efficient of common vent air purifier by granular size ", under the 1.5m/ superficial velocity of second the evaluation and test resultant filter strainability.Below in table 7 report the result represent at the minimum combined efficiency value of particle size range at the particle of 0.3 μ m to 1 μ m, 1 μ m to 3 μ m and 3 μ m to 10 μ m.Table 7 has reported that also the total filter weight after finishing evaluation and test increases (the total particle weight of being caught by filter).Higher minimum combined efficiency and total filter weight value added are corresponding to filter effect, long service life or existing strainability preferably have long service life again preferably.

Table 7

Instance number or comparative example number	Employed net	Processing to net	Initial pressure falls, the mm water column	Minimum combined efficiency (%)			Total filter weight increases, 25.4mm water column (g)
				Minimum combined efficiency (%)				0.1-1μm	1-3μm	3-10μm
				14	Example 2	Corona treatment		0.1-1μm	1-3μm	3-10μm	4.9	43	81	91	35
15	Example 2	Corona treatment and aquation charging	5.1	14	Example 2	Corona treatment	53	89	97	37.1	4.9	43	81	91	35
15	Example 2	Corona treatment and aquation charging	5.1	Comparative example 5	Comparative example 1	Corona treatment	53	89	97	37.1	4.6	36	71	86	23.8
Comparative example 6	Comparative example 1	Corona treatment and aquation charging	4.6	Comparative example 5	Comparative example 1	Corona treatment	42	81	93	33.9	4.6	36	71	86	23.8
Comparative example 6	Comparative example 1	Corona treatment and aquation charging	4.6	Comparative example 7	The ACCUAIR net	Corona treatment	42	81	93	33.9	4.6	41	80	91	26.1

As shown in table 7, compare with other the similar melt-blown non-woven nets (comparative example 5 and comparative example 6) that do not use the second cooling air to make and to have a less fiber alignment, utilize the second cooling air to make and have the melt-blown non-woven net (example 14 and example 15) of roughly longitudinal fiber arrangement and process corona treatment or corona treatment and aquation charging, fall at the 1mm water column pressure, much better minimum combined efficiency is provided.Compare with the spunbond nonwoven web-webs that can buy (comparative example 7), the net of example 14 and example 15 also has can by comparison or better minimum combined efficiency.The netting gear of example 14 and example 15 has than the better particle capturing ability of the net of comparative example 5-7 (being proved as its higher total filter weight value added).

Example 16-18 and comparative example 8

The versus speed evaluation and test falls in folding stove filter surfaces pressure

Utilize the basic skills of example 14 and example 15, melt and spray fiber arranged polypropylene net through corona treatment and aquation charging, but not through Overheating Treatment.This netting gear has 1.7MD Taber rigidity value, and is decided to be the net of example 16 hereinafter.Utilize corona treatment, aquation charging and heat treatment, the higher net of preparation rigidity.This netting gear has 2.2MD Taber rigidity value, and at the following net that is decided to be example 17.Prepare the higher net of rigidity by adding 1.5% additive poly(4-methyl-1-pentene), corona treatment, aquation charging and heat treatment.This netting gear has the 3.7MDTaber rigidity value, and at the following net that is decided to be example 18.Example 16 is to the net of example 18 and ACCUAIR spunbond polyethylene/polypropylene twisted fibres net (the Taber rigidity value with 2.1MD through corona treatment, and at the following net that is decided to be comparative example 8) sample, form the high filter element of 30cm * 27cm * 2.1cm, these filter elements have the pleat 102 of folded medium 100 as shown in Figure 7.It alongst is 13.8 pleat/10cm that filter has, and is sandwiched between the net form metallic supports (support member 110 as shown in Figure 8) and is bonded to therebetween.In a series of tests, each this filter is installed in PLEXGLAS ^TMIn the plastic frame, the transparent lateral plate of this framework makes can photograph the ruffle edge.Framework side plate contact filtration medium edge but allow pleat to move.Framework is installed on the top of vacuum tables, and is exposed to the case shape fan from directed downwards.By the synthetic dust that is formed by 50: 50 trickle test dust of SAE and talcum powder mixture is sprayed onto in the air-flow, fall up to filter pressure and to reach about 0.35 inch (0.9cm) water column under the superficial velocity of second of 1.5m/ roughly, make the filter bearing load.This has simulated natural basically loading level.Below what list in table 8 is filter explanation, MD Taber rigidity value and total filter weight value added.

Table 8

Instance number or comparative example number	MD Taber rigidity	Total filter weight increases (g)
Instance number or comparative example number	MD Taber rigidity	Total filter weight increases (g)	16	1.7	37.9
17	2.2	40.2	16	1.7	37.9
17	2.2	40.2	18	3.7	33.4
Comparative example 8	2.1	36.2	18	3.7	33.4

Then filter is installed in the pipeline that is equipped with airspeedometer, and is exposed to air, this air flows with enough speed, thereby makes pressure fall between about 0.2 inch (0.5cm) water column and 1.2 inches (3cm) water columns.Fall at 0.35 inch (0.9cm) pressure, the filter of example 16 (1.7MD Taber rigidity) begins to show tangible pleat distortion, and the pleat that shows as filter air intake side is crowded together.Fall at 0.5 inch (1.3cm) water column pressure, the filter of example 17 (2.2MD Taber rigidity) and comparative example 8 begins to show tangible pleat distortion.Even the pressure at 1.2 inches (3cm) water columns is fallen, significantly distortion does not appear in the filter of example 18 (3.7MD Taber rigidity) yet.Fig. 9 represents, falls the curve map of (representing with inches of water(in H) contrast airspeedometer reading (with specified unit representation) for the filter pressure of example 16 (curve 116), example 17 (curve 117), example 18 (curve 118) and comparative example 8 (curve 119).As shown in Figure 9, the filter of example 18 shows along with air-flow increases and linear the increase falls in pressure, and other tested filters show nonlinear reaction, and this shows that along with air-flow increases, distortion has taken place pleat.

To those skilled in the art, can carry out multiple modification and replacement, and not break away from the spirit and scope of the present invention.The content that exemplifies herein only is the usefulness of example explanation, and the present invention is not limited.

Claims

1. method that is used to make fibrous filter net, this method comprises:

A) under the situation that has first fluid stream, by nozzle array, the thermoplastic that forms fiber is melted and sprayed, to form plurality of threads, this long filament is drawn into fine fibre, and is directed to porous collection surface with direction of motion;

B) make at least that one second fluid stream impacts on described long filament or the fiber so that fiber roughly along or swing against the direction of motion; And

C) collect porous and collect lip-deep fiber, to form the non-woven net that melts and sprays, the wherein said second fluid stream is fully swung described fiber, thereby most of collected fiber alignment the direction of motion ± 20 ° in, and wherein, in the net of not heat-treating, can be the fiber of about 1cm from described online combing length to about 10cm.

2. method according to claim 1, wherein about 55% to about 90% described fiber alignment the described direction of motion ± 20 ° in.

3. method according to claim 1, wherein about 70% to about 85% collection fiber alignment the described direction of motion ± 20 ° in.

4. method according to claim 1 wherein can be from the described online combing length fiber that is about 2-5cm.

5. method according to claim 1, wherein the described fiber of Shou Jiing has the average effective fibre diameter of about 3 μ m to about 25 μ m.

6. method according to claim 1, when wherein using the full-length of 50mm, the in-plane moving direction TENSILE STRENGTH of described net is at least 2: 1 with respect to the ratio of the TENSILE STRENGTH of crossing the direction of motion.

7. method according to claim 1, when wherein using the full-length of 50mm, the in-plane moving direction TENSILE STRENGTH of described net is at least 4: 1 with respect to the ratio of the TENSILE STRENGTH of crossing the direction of motion.

8. method according to claim 1, the in-plane moving direction Taber rigidity of wherein said net is at least 2: 1 with respect to the ratio that crosses direction of motion Taber rigidity.

9. method according to claim 1, the in-plane moving direction Taber rigidity of wherein said net is at least 2.2: 1 with respect to the ratio that crosses direction of motion Taber rigidity.

10. method according to claim 1, the most surfaces of wherein said net presents striped, and this striped is corresponding to the roughly arrangement on the direction of motion of each fiber.

11. method according to claim 1 wherein places the preferentially capillarity diffusion on the direction of motion of online wetting fluid.

12. method according to claim 1, wherein the second fluid stream comprises that temperature is lower than the air of environment temperature.

13. method according to claim 12, wherein second fluid stream is mobile to the every gram polymer ratio of about 2000 gram second fluids with about 500.

14. method according to claim 1, the mode that wherein said fiber is smeared with paintbrush are layered on described porous and collect on the surface.

15. method according to claim 1, wherein said fiber are to collect the swing amplitude that the surface records in described porous, described amplitude surpasses collects 1/4th of surperficial distance from the nozzle array to the porous.

16. method according to claim 1, wherein fiber is collected in the surperficial way with cumulative swing amplitude in the described porous of arrival.

17. method according to claim 1, wherein the second fluid stream of two bursts of substantial reverse impacts on described long filament or the fiber.

18. method according to claim 1, wherein said fiber present the action of whip shape in the way that arrives described porous collection surface.

19. method according to claim 1 also is included under the temperature between about 100 ℃ and the melting point polymer, makes described nonwoven web annealing be shorter than 10 minutes.

20. method according to claim 1 also comprises described nonwoven web is carried out corona treatment or aquation charging.

21. method according to claim 20, wherein use 100ppm dioctyl phthalate particle, the particle size range of this dioctyl phthalate particle and is advanced with the superficial velocity of 7cm/ second between 10 to 700nm, under such condition, the filter quality factor Q of described net _FBe about at least 0.6.

22. method according to claim 1 also comprises making described net folding play pleat.

23. method according to claim 22, wherein pleat crosses direction of motion arrangement basically, and described folding net forms the self-supporting filter.

24. the fiber filter material of a net form formula, this netting gear has corresponding to the length direction of the prolongation that becomes the net direction with perpendicular to the narrow width of length direction, this net comprises the non-woven thermoplastic fiber, wherein great majority be arranged in into the net direction ± 20 ° in, and wherein, in the net of not heat-treating, combing plays the fiber that length is the extremely about 10cm of about 1cm from network.

25. material according to claim 24, wherein about 55% to about 90% fiber alignment described one-tenth net direction ± 20 ° in.

26. material according to claim 24, wherein about 70% to about 85% collection fiber alignment described one-tenth net direction ± 20 ° in.

27. material according to claim 24 wherein can be from the described online combing length fiber that is about 2-5cm.

28. material according to claim 24, wherein fiber has the average effective fibre diameter of about 3 μ m to about 25 μ m.

29. material according to claim 24 when wherein using the full-length of 50mm, becomes net direction TENSILE STRENGTH to be at least 2: 1 with respect to the ratio of the TENSILE STRENGTH of crossing into the net direction in the face of described net.

30. material according to claim 24 when wherein using the full-length of 50mm, becomes net direction TENSILE STRENGTH to be at least 4: 1 with respect to the ratio of the TENSILE STRENGTH of crossing into the net direction in the face of described net.

31. become net direction Taber rigidity to be at least 2: 1 in the material according to claim 24, the face of wherein said net with respect to the ratio that crosses into net direction Taber rigidity.

32. become net direction Taber rigidity to be at least 2.2: 1 in the material according to claim 24, the face of wherein said net with respect to the ratio that crosses into net direction Taber rigidity.

33. material according to claim 24, wherein Wang most surfaces presents striped, and this striped is corresponding to the roughly arrangement on one-tenth net direction of each fiber.

34. material according to claim 24 wherein places online wetting fluid preferentially becoming capillarity diffusion on the net direction.

35. material according to claim 24, wherein use 100ppm dioctyl phthalate particle, the particle size range of this dioctyl phthalate particle and is advanced with the superficial velocity of 7cm/ second between 10 to 700nm, under this condition, the filter quality factor Q of described net _FBe about at least 0.6.